Method of making coils.



R. VARLEY.

METHOD OF MAKING COILS. APPLICATION FILED 001214, 1911.

11,073,059. Patented Sept 9,1913.

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M I? INVENTOR. 444 MMYMa 0 \7w I s I R. VAR BY, METHOD OF MAKING GOILS.4

APPLIUATIOK 1I LE D OCT. 14, 1911.

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Patgnted Sept. 9, 1913.

' w'russszs. I fimma 1 winter, or memwoon, new was; essence. tovanrrr'nurnm j mama's comm, or JERSEY cu t, H'Ew JERSEY, A concur-A1101!or NEW JERSEY- To all'whom it may concern:

I Be ts-known thstl, Rrcmm Venice, a citizen of the United States ofAmerica, and residing at Englewood, in. the county of Bergen and Stateof New Jersey, have I invented a new and use'fiil Methoei oi Malt ingOoilsg of which: the iollowing is a: full, clear, and exact description,reference been lied to theaccompanying drawings, wln form pert oi this,or ation.

My invention, subject has for its primary ob ect iozmaztiomof coils inwhich the croessectional shape or der tension", anti its removal fromthe mandrel reoctione! strains are thereby set up tend tomisehapeitscross-sectional dcsi n. Strains also arise in subseqmnt han ling and theapplication or impugnetion of insulation, whlch also readily di art inthe culinary coil, its cross-sectional shape. This ietorti'on or bulgingof the grouped or benched wire presentsnot only a; chilieulty inadapting the malformed coil to appfiratus in which standard or fixedalimensi'onal coil spam obtains, but also causes undesirable variationspredetermineei voltage or potential eap'aciextg oi'the coil.

The 0- mentmn 1 difficulties', while arising m for practically'allelectric apparatus, are pecu' iar to, and clearly instalneed in, thecase of static: transformers in which, as is commonly known, the capesity or transformation is dependent the size and the relatiye number ofturns of wire iii the coils for determination of the ratio optconversion of the potential or volt age. In transformer coils, therequirement that the coil be e etrical and compact in cross-sectional epe arises not only from the desirzrbility of keeping the transformer(lown to moderate size (by reason: of, the not that the coii elementschange as to the cubeof the linear dimensions while changes in the caseoccur as to the square of the lineer dimensions) but also firom thenecescity of non variation' of prefletemiined capacity or ratio oitranion; for

of this epplication, is a method 0! making electric corls and. it-

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Specification of mm: I'me'nt. I P t 'it a g m, 9;, 9 3, 5mm mama, m1. m1r5. cam.-

tortion'oftheooil places the wire oi differ I cnt layersof. the windingsuch irregular ynxtapi'losition In;v to vary the potential of co 3 Ithas been the practice to interpose thick insulation between differentlayers so as to. preserve the potential difference of these difterentlayers, but such spacing. results in IoFFIGE-SF undue Increase-m size ofthe coil and COHSB- quent undesirable enlargement of apparatus.

to form as coil which will retain its true ini:

tial shape without thceid of means which provide a mthotl by which coilsmay be qmckly and accurately formed of any desirecl gage windingendwhich enables their iormwtwn' elther smgly or in multiple manner. woundupon the coil-former or mandrel, un-

In the accompenying drawings I have llustrated preferable apparatuswhich may be an oyed 1n carrying out my invention. It wil be premised,however, that different and distinct fiorms oat apparatus may beemployed and that changes may be made in the apparatus shown withoutdeparting irons my invention It will also be under- By my'methorl oimaking coils I am able 330ml: thatmy invention is not limiter} to theproiluction of any particular form 01'. charecter of coil; the inventionbeing equally appliable to the making of dynamo, motor, transformer andother induction coils.

F1gu re It is'a side elevation of e plurality oi coil-mg ma nclrels orfiormers which may be employed inccrrying out my invention; In th1s=v1ewI indicate a plurality oi coils in pc ss oi making; Fig. 2 is a top planV ew \o the some; Fig; 3 is a. perspective view, partly in sectionshowing a coil wound upon a tanner and having; partly in full lines-andpartly in dottedlines, ind-icetcd binding element incorporated the coil;Fig. 4 is a similar view showing modifi ed manner of applying narrowexternal binding elements to the coil, such as small w-rrc strwnds; Fig.5isa sectional Vie ii1 dicoting diagram the manner of severing .tionalview showing; a pluralitycf coil formers and manner of presenting thefinal or exterior binding element to the coil for ers preparatory towinding of the coil; Frg. 8 is a similar view showing manner ofpresenting binding material to the formers in the progress of theformation of coils; Fig. 9 is a similar butfragmentaryview showingmodified manner of incorporating the binding element in the coil; Fig.10 is a sectional view through a plurality of formers and indicatingmanner of applying a common binding element .to the plurality of coilformers; Fig. 11 is a fragmentary view/corresponding with Fig. 1butshowing means whereby a supply of binding material may be operativelycarried by the coil former.

and also showing the former as having individual clamping means forholding the exterior binding element during the making of the coil, aswill be hereinafter more fully brought out; Fig. 12 is a sectional yiewcorresponding with Fig. 10 but showlng manher of tying or terminallyanchoring the exterior binding element; Fig. 13 is .a frag-' mentarysectional view of a coil showing the exterior binding element terminallyanchored or held against displacement by the layers of the winding, andas applied in the manner indicated in Fig. 12; Fig. 14 isa sectionalview of a coil former on a line extending radially from the center ofthe coil former to the corner thereof and indicating modified manner ofapplying binding tape; as preferably for corner binding of the coil;Fig. 15 is a plan view of a section of binding strip of modified form;Fig. 16 is a similar view indicating another form of binding strip, bothforms to be hereinafter more fully referred to; Fig. 17 is anelevational view of a finished coil made in accordance with myinvention; and Figs. 18 and 19 are sectional views of coils showingmodified manner ofapplying binding tapes, and to be hereinaftermore-fully referred to. v

In carrying out my invention I may form a single coil or form aplurality of coils contemporaneously. Broadly stated, I may firstpresent to a coil mandrel or former an exterior binding strip or strandpreparatory to winding of the wire. I then apply the winding insuperposed layers of conductor turns, and during the progress of windingapply an interior binding element preferably uniformly spaced atintervals in the development of the winding. These interior bindingstrips may comprise thin strips of paper, cambric', or very thinfiber-board and I preferably so incorporate them in the coil as to allowof end or terminal extensions beyond the body of the coil, that is,beyond its axial faces, which extensions may be bound tightly to andreinforce against displacement the side exterior wires of the coil bymeans of the first mentioned exterior binding element which maycompriseadhesive tape or strip or may take ,the form of sultable ductilewire. If wire is employed as an exterior binder and is fed to'the man'-drel' preparatory to the coiling operation, a

mandrel or former such as shown in Fig. 4 may be employed, which mandrelis shown as having notches or recesses 5 to abcommodate such wires. Forthe sake of convenience the exterior and interior binding elements maybe termed primary and secondary, respectively.

While the above description is a broad, statement of my invention, I ,donot wish to be understood as limiting myself to the application of anynumber of binding strips nor to the application of binding strips to anyparticular point or points in the coil; it being apparent that thenumber and position of the strips may be varied as desired and bedependent upon the character of the coil concerned.

I' have statedthat different forms of apparatus may be employed incarrying out my method but the apparatus illustrated is desirable byreason of the particular provision made for enabling quick and accurateapplication .of thebinding elements. Such apparatus, described in myco-pending application, Serial No. 654,7 55 I will now refer togenerally in delineating the manner of forming coils by my method.

The numeral 2 represents a rotatory shaft or spindle as forming the mainoperative periphery of the disk to the body of the former as shown inFig. .101 The recesses 5 enable binding tapes to be so presented andapplied as to cause them to extendbeyond the ends of the coil. This isan important feature of my method as it enables the application of tapesof length sufiicient to overcome abortive binding or tying functionarising from take-up or drawing in of the ends of tapes, due to thebinding of the turns of winding of one layer on those of another layer.

In making the coil, the binding element 6 may be fed from a suitablesource of sup- (see Fig. 7 such as a magazine or ply -7 ro l, and ispresented to the mandrel or former 3 preparatory to application of thewinding. To prevent displacement of the tape 6 clamping means 8 areemployed to hold the tape at ing zone of the ormer 3. As shown, theseclamping means comprise spring-clips 9'unoints outside of the windderwhich the tape is inserted as it is fed to the former. In applying thetape 6 to a plurality of mandre s or formers 3, the formers are arrangedso as to bring the recesses Din alining re 'stration. This enables thetape 6 to be readily fed from a common source to theseveral mandrcls.When applied tolhe mandrel in multiple or plural arrangement, I providean overflow or reserve accumulation of the tape 6 at points a, (see Fig.7), for the purpose of providing suflicirnt length of tape for wrappingaround the superficial fare of the coil when completed, instead ofspacing the formers from one another a. distance to provide such lengthof tape. After applying the tape 6 the winding is 'irescn'trd to theformer in each case for the rotatory building of. the coil, and atintervals in the progress of winding I- feed binding'tapc or element 10to the layers, preferably, at uniform inter. vals through the body ofthe coil. 'lhis manner of applying-thebinding strip 10 isindicated in l!lgs. 1, 2, 8, 5), l0 and 11 and corrospomls with the mode of applyingthe tape 6 in so far as feeding from a source of supply to a singlemandrel or a plurality of mandrels or formers. The tape 10 in mssin fromasource of sn 1] -11 is a plied across the layer or layers of windingvengthwise of the coil and held against displacement by the binding cli)S 8, after which succeeding layers of winding may be aplied to the coiland the up lication of binding tape 10 then repeated, the alternateapplication'of winding and bindin element being dependent upon the size0 the coil and the number of binding strips desired to be incorporatedtherein.

In Figs. 18 and 19 I show manner of tying-the coils in sections. A partof the coil may be wound to form layers of any particular size and shapeand thenf-bound by a. ta e 10 after which other portions of the coi maybe progressively wound and bound in asimilar manner. The sections sowound and tied may be symmetrically apportioned or not, as desired. Theview illustrated in Fig. 19 indicates how certain portions of the coilmay be so wound asto' cause the ti'ed or bound ortionseto embrace andsupport against displacement an intermediatelayer of winding 13.

the formers' This severing of to 10 may be cheated by rotating the s orformers during which severing apparatus such as knives 12 maybe presento the ta es. This is clearly indicated in Figs. 1 an 5. In Fig. 5 theknife 12 is shown as comprising a pivoted blade which may be moved intoand out of the path of travel of the tapes 10 in the rotation of theshaft 2. The severing of the tapes 10 enables the exte rior binding tape6, when employed to'be severed at points between tie coi s and wra edabout each unit in the plane occupied tapes 10. The sections of to e 10,

length as to provide the terminal portions 18 which may overlap at theend faces of the coil the superposed layers of winding as the tape 6 isdrawn taughtly and tied to the body of the coil, or as I ave brought outabove, the ends of the tapes 10 may .be bound within the coil,as'iridlcated in Figs, 18 and 19.

.In Fig. 13 the'coil b is shown as having theexterior bindin tape 6terminally anchored'amongthe final layers of the windingof the coi Anadvantageous feature of this manner of tying or fastening 6 is that theterminal portions 0 the tape are firmly locked in the coil in aself-contained manner similar to the locking of the tape 10 as indicatedin Figs. 18 and 19. This locking effect of the tape 6 is illusformer3 asbeing provided with ta clamping means 8 disposed at each si e thereof sothat the end of the tape 6 may be passed over the top of the coil asclearly shown and held under a clam while a layer a of wire is appliedafter 'w ich the ta e 6 ma be severed at a point practically ush wit-1the side or end of the coil, as at d, and the opposite end e of the ta e6 then passed over the coil and held by "t e other clam while a final orfinishing layer f of wind i ng may be applied. Of course,

any suitable aldhesive cambric, or the bm or may be wrapped about thecoil and-tied by other separate means. Inanchoringthe tape 6 within thecoil'it is desirable that the to e be held taughtly across the coilin'the'application of thefinal layers of winding or such layers ofwinding as serve to lock the to e, by clampin means at each side of tieformer ass own in Fi' s. 11 and i2, so as to cause the tape to bintightly on thecoil as thelapglication of turns of the layer of windingrows the ends of the tape inwardly. This manner of holding the tapeby'clamping means may obtain in the case of locking or 'faste'nin thetapes 1 0 when nip lie'd as shown in F1gs.'18 and 19.

- 11 building u coils according to the present invention, 7 0 bindingelements are best fed to the coils, as shown, in a direction arallel tothe axis of the mandrel or almed carrier by each coil, preferably are 0such' adhesive bmder 6 may be cmp'lpiyed, such as the tape 3 trated inBig. 12 in which is shown the mandrels, as the case may be; that is,transverse to the conductor turns.

The binding or tying of the coil against distortion is preferably atuniform points or intervals along the body of the coil as indicated bythe positions of the binding strips 6 in Fig. 17 This is clearly broughtabout by employing a suitable guide, such as the recesses 5, uniformlyor symmetrically disposed in the members 4:. The'recesses 5.

ing tapes within the zone of the curved corner portions of the windingenables the formation of an angular coil having true shape and compactin size, for it allows the turns of the winding to geometricallyposition or adjust themselves as they draw across or over the cornerportion of the coil. With the corners free from the binding tape theturns symmetrically contact with one another in' a, staggered oralternating manner at these points so that the layers are evenly anduniformly applied, resulting in the abilityto wind coils of a determinedor given number of layers having also a required number of turns. Theseconditions make it possible to wind-acoil for any certain predeterminedelectric'capacity. As the turns are held in 1proper relationship at thecorners of the coi the crossing of the winding (which necessarily takesplace in the recip-- rocable feeding of the turns across the coil formerto produce the layers) occurs in the body intermediate the corners,thereby resulting in a long or moderate crossing effect which does notabruptlybend the w re or irsregularly pile up the winding at thesecrossing points, to the corner of the coil also results in bulky andunsymmetrical corner formation due to the fact that the radii of thecorner turns of the winding are very small in most cases and produceuneven and center-bound condit-ion of the tapes at the corner orcornersof the coil. By binding the coil at these points contiguous to thecorner arcs of the turns of wire the binding tape operatively contactsthroughout its whole width with coil at points contiguous to thecurvilinear Application of binding material portions thereof permitsofthe preferable employment. of tapes of .a constant unit of width forcoils of'various sizes.

In certain size angular coils there is present sometimes a tendency tospreading or fanning out'of the corner portions of the coil uponiitsremoval from the former or mandrel, This maybe overcome by binding thecorner of'the coil with a narrow a layer or turns of the winding,'afterwhich I apply a second and similar binding tape 6" and proceed with thewinding operation and, if desired, anchor the ends as in the case of atape 6 as indicated in Figs. 12 and A 13 or tapeslO as indicated inFigs. 18 and 19. To provide an interlock between the two tapes 6" and 6"and'the body of the coil, one or two turns of the winding of the secondhalf portion 9 of the coil may be applied before the application of thetape 6", thereby causing the turns of wire to lock the ends of the firstmentioned tape 6 before the application of the tape 6" and the finishingof the coil.- As the tapes 6' and 65 are applied 'zto the corners of themandrel, the coil former shown is formed with the corner recesses 5similar to the recesses 5. The fastening or interlocking of tapes 6 and6" may ,also apply to the application of tapes 10 or tapes 6 and 10.

Asshown in Fig.v 9 the tapes 10 may be corrugated as they ass from thesource of supply 11' to the coil formers so that-the tapes may readily.adjust themselves to the cross-sectional contour of the turns of wirecomprising the layers of the winding. This,

of course, is only necessary in the case of wire of materially largegage, for the reason that in large gage wire the application of theturns of wire is made in an alternate or staggered manner so'that oneturn lies interjacent opposing turns and effects corrugation of thetapes 10 with resultanttion of those members. To overcome this efiect Ieither corrugate the tape 10 as shown in Fig. 9, in a continuous mannerso as to bring about the adjustment above described, or cor'rugate itatpoints intermediate thecoil formers so as to permit of corrugations h tostraighten out under the travel or creeping movement of the tape due tothe application of the wire and thereby relieve said tapes frominjurious "strains. This i's'clearlyindicatcd in Figs. 8 and 10, thelatter view illustrating the take-up movement of the tape. in thewinding 'of the coil. The tapes 10 may be corrugated in any suitablemanner such as by passing through corrugating means or rolls 14 from thesource of supply 11 to the coil formers.

Inlieu of corrugating the tape .10 it may ation.

has

I do not desire to claim in this application the apparatus shown inconnection with mymethod, as such mechanism forms subject-matter of myabove-mentioned co-pendmg application, Serial No. 654,7 and also myco-pending application, Serial No. 654,753. a

Many changes may be made in the invention without departing from itstrue spirit. Coils may be formed with interior binding tape incorporatedtherein and then removed from the mandrel or former and subse quentlybound by exterior tapeorfother means and other changes may be made inthe manner'of a plying the binding elements. For instance, eithertapeslO or 6 may be employed alone to bind the coil. Coils wound inaccordance with the method here-' inbefore described may be removedfromtheir respective winding mandrels and may be subsequently handled toany necessary extent without undergoing distortion as a whole or withoutdisplacement of thelay- 'ers of turns relative to each other.

\ What I claim and desire to secure by Letters Patent is:

,1. A method of -making electric coils which comprises winding-aplurality of conductors into coils on a"-plurality pf-coilformers,feeding a continuous binding elementto the coil-formers and into contactset my hand.

with the conductors in the progress of winding, and adjusting theportions of the binding element between the coil-formers in such manneras to permit the necessary take-up or creep of said binding element onthe coilformers to occur without rupture of the binding element in thebody of a coil.

2. A method of making electric coils which comprises winding a pluralityof conductors into coils on a plurality of coilformers in substantiallyaxial alinement, feeding a continuous binding element to thecoil-formers and into contact with the conductors in the progress ofwinding and in a direction approximately parallel to the common axis ofthe coil-formers, and adjusting the portions of the binding elementbetween the coil-formers in such manner as to permit the necessarytake-up or creep of said binding element on the coil-formers to occurwithout rupture of the binding element in the body of the coil.

3. A method of making electric coils which comprises winding a pluralityof con ductors into coils on a=plurality of coil formers, feeding acontinuousbinding element to the coil-formers and into contact with theconductors in the'process of winding, and providing reserve portions ofsaid binding element between the coil-formers 1n orderto permit thenecessary take-up or creep of said binding element on the C011- formersto occur without ru ture of the binding element in the body 0 a coil.

4:. A method of making electric coils which comprises winding turnsof aconductor on, a suitable mandrel to form alayer, placing a bindingelement in contact with such layer and holding the same in position withyielding tension'so adjusted as always to be less than the breakingstrength of said binding element, and winding another layer of conductorturns on the binding element thus held, whereby the creep of the bindingelement caused bythe appllcation of the second layer may :occur withoutrupture of the binding element between the layers.

In testimony whereof, I have hereunto RICHARD VARLEY.

Witnesses:

M. A. Bzurrrr, M. A. KELLER. 4

